U.S. patent application number 15/212165 was filed with the patent office on 2017-08-31 for photovoltaic mounting system for solar tracker array.
The applicant listed for this patent is SolarCity Corporation. Invention is credited to Robert Haas, Johann Fritz Karkheck, David Molina, Kathryn Austin Pesce.
Application Number | 20170250648 15/212165 |
Document ID | / |
Family ID | 59679037 |
Filed Date | 2017-08-31 |
United States Patent
Application |
20170250648 |
Kind Code |
A1 |
Haas; Robert ; et
al. |
August 31, 2017 |
PHOTOVOLTAIC MOUNTING SYSTEM FOR SOLAR TRACKER ARRAY
Abstract
Mounting systems are disclosed for attaching photovoltaic
modules to torque tubes. Such systems can include saddle brackets
that maximize space along a torque tube by sharing torque tube
mounting holes between adjacent brackets. The brackets can be
positionally stable on the torque tube prior to complete
installation to enable a single installer to assemble a complete
tracker array.
Inventors: |
Haas; Robert; (Greenbrae,
CA) ; Molina; David; (Oakland, CA) ; Pesce;
Kathryn Austin; (San Francisco, CA) ; Karkheck;
Johann Fritz; (Petaluma, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SolarCity Corporation |
San Mateo |
CA |
US |
|
|
Family ID: |
59679037 |
Appl. No.: |
15/212165 |
Filed: |
July 15, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62299863 |
Feb 25, 2016 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F24S 25/634 20180501;
Y02E 10/47 20130101; F24S 25/65 20180501; Y02E 10/50 20130101; F24S
25/63 20180501; H02S 20/32 20141201; F24S 30/425 20180501; F24S
25/632 20180501; F24S 25/12 20180501 |
International
Class: |
H02S 20/32 20060101
H02S020/32 |
Claims
1. A photovoltaic (PV) module mounting system for a solar tracker
array comprising: a first PV mounting bracket comprising a first
saddle portion for supporting a first PV module, the first PV
mounting bracket further comprising a first collar portion shaped
to fit around a portion of a torque tube, the first collar portion
having at least one first mounting hole; and a second PV mounting
bracket comprising a second saddle portion for supporting a second
PV module, the second PV mounting bracket further comprising a
second collar portion shaped to fit around a portion of the torque
tube, the second collar portion having at least one second mounting
hole aligned with the first mounting hole, the first and second
mounting holes for receiving a mechanical fastener to attach the
first and second PV mounting brackets to the torque tube.
2. The PV module mounting system of claim 1, wherein each of the
first and second saddle portions comprise a plurality of attachment
tabs arranged to constrain a top portion of a PV module.
3. The PV module mounting system of claim 2, wherein each of the
first and second saddle portions comprise a plurality of ledge
portions arranged to constrain a bottom portion of a PV module.
4. The PV module mounting system of claim 1, wherein the first and
second collar portions respectively comprise first and second
alignment tabs arranged to oppose the first and second mounting
holes, each of the first and second alignment tabs fitting into the
torque tube.
5. The PV module mounting system of claim 4, wherein the first and
second collar portions respectively comprise first and second
alignment portions arranged adjacent to the first and second
mounting holes, the first and second alignment portions configured
to provide leverage points for aligning the first and second
mounting holes with a fastener opening of the torque tube.
6. The PV module mounting system of claim 1, wherein each of the
first and second PV mounting brackets comprises at least one
stiffening rib.
7. The PV module mounting system of claim 1, wherein the first and
second collar portions respectively comprise third and fourth
mounting holes arranged to oppose the first and second mounting
holes, the third and fourth mounting holes being configured to
overlap for receiving a second mechanical fastener.
8. A photovoltaic (PV) module mounting bracket for a solar tracker
array comprising: a collar portion shaped to mount to at least a
portion of a torque tube of a solar tracker array, the collar
portion comprising at least one mounting tab having at least one
mounting hole, the at least one mounting tab being positioned to
overlap with another mounting tab of a second PV mounting bracket
to share a fastener for mounting to a torque tube; and a saddle
portion having at least one ledge portion configured to support a
bottom portion of a PV module and at least one attachment tab
configured to resiliently retain an upper portion of the PV module
to the at least one ledge portion.
9. The PV module mounting bracket of claim 8, wherein the collar
portion comprises an alignment tab configured to insert into an
opening of the torque tube.
10. The PV module mounting bracket of claim 9, wherein the
alignment tab comprises a folded portion of sheet metal.
11. The PV module mounting bracket of claim 10, wherein the folded
portion is attached to a wall portion of the collar portion.
12. The PV module mounting bracket of claim 8, wherein a wall
extends between the collar portion and the saddle portion, wherein
the wall comprises at least one bumper portion.
13. The PV module mounting bracket of claim 12, wherein the least
one ledge portion extends in a first direction and wherein the
bumper portion extends in an opposite direction from the first
direction to prevent the saddle portion from backing off the PV
module.
14. A photovoltaic (PV) mode mounting bracket for a solar tracker
array comprising: a wall member; a plurality of saddle supports
extending from the wall member, the plurality of saddle supports
for supporting one edge of a PV module; a plurality of collar
members extending from the wall member, the plurality of collar
members arranged to mount onto a torque tube.
15. The PV module mounting bracket of claim 14, wherein the wall
portion comprises at least one reinforcement rib extending
laterally away from the wall member.
16. The PV module mounting bracket of claim 14, wherein the
plurality of saddle supports comprise upper attachment tabs
configured to apply compressive force to the one edge of the PV
module.
17. The PV module mounting bracket of claim 16, wherein the
plurality of saddle supports comprise ledge portions configured to
support the one end of the PV module against the compressive force
provided by the upper attachment tabs.
18. The PV module mounting bracket of claim 14, further comprising
a tab portion extending from the wall member, the tab portion
configured to support a mechanical fastener for connection to the
torque tube.
19. The PV module mounting bracket of claim 18, further comprising
an alignment tab extending from the wall member, the alignment tab
configured to extend into an opening of the torque tube.
20. The PV module mounting bracket of claim 14, wherein the
plurality of collar members are configured to resiliently bias
against the torque tube.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This claims the benefit of U.S. Provisional Application No.
62/299,863, filed on Feb. 25, 2016, which is hereby incorporated by
reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] Solar trackers are used to rotate photovoltaic (PV) modules
to keep them perpendicular to the direct rays of the sun. Keeping
the array of PV modules at this orientation increases and ideally
optimizes the amount of energy that can be generated by the array,
because energy generated by a fixed tilt array drops off with the
cosine of the angle of incidence of solar rays on the surface of
each panel. Because tracker arrayscost more and have relatively low
ground surface area utilization due to the required row-to-row
spacing to prevent shading, trackers are typically used only in
medium to large sized arrays (e.g., .gtoreq.1 megawatt). Although
trackers add an additional cost per watt over fixed ground-mount
systems, the cost is typically recouped on arrays of this size.
Hardware and operating cost reductions will further expand the role
of trackers in energy generation to even smaller sized arrays, that
is ones below 1 megawatt.
[0003] In a single-axis tracker, photovoltaic modules are suspended
above the ground in one or more horizontal rows, connected to a
beam known as a torque tube. The torque tube, generally oriented
along a North-South axis, is attached to a drive mechanism actuated
by a controller to incrementally rotate the photovoltaic array in
place over the course of the day to maintain a relatively constant
angle with the sun as the sun progresses through the sky.
[0004] Some more sophisticated trackers known as dual-axis trackers
not only rotate modules from East-to-West but also tilt modules
towards the equator. With these trackers, modules are usually
clustered together in individual sections, spaced apart from one
another since they have to have greater spacing due to intra-row
shading (shading of one section by an adjacent section in the same
row), as well as inter-row shading (shading of one row by the
adjacent row).
[0005] Because tracker arrays require very little post installation
maintenance, the viability of these projects often turns on the
projected rate of return derived from comparing the fixed value of
the energy generated over the lifetime of the system versus the
upfront costs of installation. In a multi-megawatt project, cost
reductions of pennies per watt can be the difference between a
project being viable or too expensive. Therefore, tracker designers
are always seeking innovations to lower installation and hardware
costs.
[0006] Accordingly, there remains a need for photovoltaic module
assembly hardware that can make installation of solar tracker
arrays more efficient and cost effective.
BRIEF SUMMARY OF THE INVENTION
[0007] Various embodiments of the invention provide new and
improved methods and systems for attaching solar panels to a torque
tube of a solar tracker. Various embodiments will reduce costs and
increase installation speed over conventional methods and systems.
Such brackets can connect quickly and efficiently to PV modules by
"snap" fit type connections, e.g., fastener and tool-free. However,
some brackets can utilize fasteners for connection to a PV
module.
[0008] Advantageously, many these brackets enable a single
installer to assemble a solar tracker array efficiently and quickly
by utilizing features that stabilize a PV module onto a torque tube
prior to final installation. PV modules are not often overly heavy,
but instead very cumbersome to handle due to large surface areas.
Thus, array assembly typically requires at least two installers
with one being responsible for holding the PV module in place while
the other attaches the PV module to the torque tube. However,
brackets disclosed herein allow a single installer to temporarily
place a relatively large and cumbersome PV module in a non-final,
but stable, position on the torque tube, such that the installer
can "let go" of the PV module to access other portions of the
assembly to complete installation.
[0009] The brackets and/or clamps as disclosed herein can also be
used for mounting PV modules in other types of PV installations,
for example in fixed arrays. Such fixed arrays can include fixed
tilt ground-based or roof-top mounting systems, where such systems
can have individual or common tubular members to which the brackets
and/or clamps can be used to attach PV modules. These and other
embodiments are shown and discussed in greater detail in the
drawing figures and corresponding detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIGS. 1A and 1B show mounting brackets for a solar tracker
according to various embodiments of the invention.
[0011] FIGS. 1C through 1G show processes for mounting brackets for
a solar tracker according to various embodiments of the
invention.
[0012] FIGS. 1H and 1I show mounting brackets for a solar tracker
according to various embodiments of the invention.
[0013] FIG. 2 shows a mounting bracket for a solar tracker
according to various other embodiments of the invention.
[0014] FIGS. 3A and 3B show a mounting bracket for a solar tracker
according to still further embodiments of the invention.
[0015] FIG. 4 shows a mounting bracket for a solar tracker
according to additional embodiments of the invention.
[0016] FIGS. 5 through 10C show incremental steps of a process for
installing photovoltaic modules on a torque tube with the mounting
bracket of FIG. 4 according to various embodiments of the
invention.
[0017] FIGS. 11A and 11B show a process for uninstalling a
photovoltaic module from a torque tube with the mounting bracket of
FIG. 4 according to various embodiments of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Referring now to the drawing figures, FIG. 1A illustrates a
mounting system for a solar tracker according to various
embodiments of the invention. The system can include bracket 100
that can include wall member 101, which can extend along a plane.
Various features can extend from wall member 101, including for
example, a plurality of ledge portions 105, plurality of attachment
tabs 110, and collar portion 115. Such features can be formed from
by cutting and bending shapes from wall member 101.
[0019] FIG. 1B shows an alternative arrangement of bracket 100,
which shares many of the same features of the bracket shown at FIG.
1A, where wall member can include reinforcement portions 102.
Reinforcement portions 102 can extend as ribs along wall member 101
and protrude outwardly or inwardly from a PV module that bracket
100 mounts to. Bumper portions 104 protrude outwardly from a PV
module that bracket 100 mounts to. In this manner, bumper portions
104 can act as a spacer and bumper to a directly adjacent PV module
and bracket having a similar reinforcement rib facing the opposite
direction. This arrangement can help prevent excessive movement
between PV modules and brackets, and thus help prevent the PV
modules from backing out of the brackets due to wind-induced
bracket sway. In addition, gussets 103 can be located at various
locations along bracket 100, primarily where bends are located to
help strengthen bracket 100.
[0020] With reference to both FIGS. 1A and 1B, ledge portions 105
can extend from one side of wall member 101. Ledge portions 105 can
support a bottom surface of a PV module. As shown, ledge portions
105 can extend in a extend in a generally transverse (e.g., 90
degrees) manner from wall member 101, however, ledge portions 105
can also extend from wall member 101 at non-transverse angles
(e.g., 70-85 degrees) as well, in order to provide spring bias
(i.e., clamping force) against a PV module. Ledge portions 105 are
shown extending as tab shaped elements having planer profiles.
Here, ledge portions 105 are depicted to be rectangular, however,
other shapes are possible as well, such as circular or
triangular.
[0021] Attachment tabs 110 can also extend from wall member 101 to
help support upper portions of a PV module. Attachment tabs 110 are
shown as hook-like protrusions that extend laterally from wall
member 101 down towards ledge portions 105. Attachment tabs 110 can
extend at angles that intersect planes that extend along ledge
portions 105. Attachment tabs 110 and ledge portions 105 cooperate
to constrain a PV module, and hence make up portions of a so-called
"saddle" for securing one side of a PV module to a torque tube. In
some cases, attachment tabs 110 can form an electrical connection
with a PV module to serve as a grounding path.
[0022] Collar portion 115 is generally shaped to fit around a
torque tube, and is formed about a shape that is complimentary to a
torque tube, which here is hexagonal for fitment onto round or
hexagonal torque tubes. Other variations are possible too, such as
rectangular or rounded shapes. Collar portion 115 is shown as a
plurality of petal-like collar members 116 that extend laterally
from wall member 101. Three of such collar members 116 are depicted
in FIG. 1A-1B, but more or less of collar members 116 can be used.
In addition, one or more of collar members 116 can include mounting
holes 118 that can serve as attachment locations for additional
fasteners or fastening mechanisms such as hooks or clasps.
[0023] Collar portion 115 may include rivet tab 120 with rivet hole
121 for attaching saddle bracket 100 to one side of a torque tube,
and alignment tab 125 for attaching bracket 100 to an opposite side
of the torque tube. Alignment tab 125 can include a protrusion for
fitting into an opening of a torque tube. Alignment tab 125 can be
formed from a portion of wall member 101, by folding for example.
Alternatively, alignment tab 125 can be formed from additional
material, for example a sheet metal portion that is spot welded,
riveted, or bonded to wall member as depicted at FIG. 1B.
[0024] Rivet hole 121 and alignment tab 125 can be located on or
proximate to the same plane that wall member 101 extends long. This
arrangement can help maximize space along a torque tube by allowing
sharing of fastener holes between adjacent brackets of directly
adjacent first and second PV modules. That is, a first bracket of a
first PV module can share the mounting holes on a torque tube with
a second bracket of a second PV module. This can be performed by
each alignment tab being located within a shared hole within the
torque tube while the rivet tabs 120 overlap to such that rivet
holes 121 are concentrically located over a shared rivet hole of
torque tube. While it is not necessary that rivet hole 121 and
alignment tab 125 can be located on the same plane of bracket 100
to achieve these goals, such an arrangement helps maximize space
and evenly distribute stress along the array, while providing a
uniform arrangement of brackets. It should be appreciated that a
rivet is not the only possible means of attachment--a screw, bolt,
or other suitable fastener could be used with rivet tabs 120 to
attach bracket 100 to the torque tube.
[0025] In various embodiments, a torque tube may be fabricated to
include mounting holes and alignment holes along its length so that
brackets 100 may be used to attach several photovoltaic modules to
the torque tube at the same orientation. As shown at the variation
of bracket 100 as shown at FIG. 1B, rivet tab 120 can also include
pull hole 122, that can serve as a grabbing location for a tool to
leverage rivet hole 121 into location over a matching hole of a
torque tube while alignment tab 125 is located within the torque
tube. Alternatively, a hook or other shape could be used for this
purpose.
[0026] In various embodiments bracket 100 will be made in
left-handed and right-handed versions with the significant
difference being the orientation of rivet tab 120 and alignment tab
125 is opposite. Alternatively, holes may be formed in the torque
tube to allow the same bracket to be used on the left side and
right side. In various embodiments, bracket 100 may be formed out
of a single piece of sheet metal that is stamped and bent into the
appropriate shape. However, it may also be fabricated from
roll-formed metal, casting, or some other process.
[0027] FIGS. 1C and 1D depict a sequence for installing
photovoltaic modules PVM on a torque tube using bracket 100. Left
and right-handed brackets 100 can be installed on each side of
photovoltaic module PVM prior to placing photovoltaic module PVM on
the torque tube. At FIG. 1C, attachment tabs 110 are secured onto a
top portion of photovoltaic module PVM by, for example, hooking
ends of attachment tabs 110 onto grooves or ledges of photovoltaic
module PVM. In the view shown, bracket 100 can then be rocked or
pivoted counter-clockwise or "snapped" to the position shown at
FIG. 1D such that ledge portions 105 secure to a bottom portion of
photovoltaic module PVM. After snapping into place, the resilient
nature of attachment tabs 110 and ledge portions 105 can forcibly
hold photovoltaic module PVM in place by applying compressive force
to photovoltaic module PVM.
[0028] FIGS. 1E and 1F depict a sequence for positioning
photovoltaic module PVM and attached brackets 100 onto torque tube
TT. At FIG. 1E, an installer can place one side of photovoltaic
module PVM onto torque tube TT and then push photovoltaic module
PVM according to the directional arrow to place collar portion 115
onto torque tube TT. As shown, a flat angled portion of bracket 100
may serve as a ramp to guide collar portion 115 onto torque tube
TT. At FIG. 1F, after collar portion 115 is over torque tube TT,
photovoltaic module PVM can be rotated until alignment tab 125
falls into an opening of torque tube TT. While secured by alignment
tab 125, photovoltaic module PVM can be temporarily left hanging in
the position shown to allow the installer to install an adjacent
photovoltaic module PVM or rivet bracket 100 to torque tube TT.
[0029] In some cases, collar portions 116 can be arranged to
resiliently deform when securing bracket 100 to torque tube TT. As
such, collar portions 116 can be angled to resist bending and thus
provide some spring bias. Such an arrangement can help secure
bracket 100 and prevent movement after installation, but also can
challenge natural alignment of rivet hole 121 with a corresponding
hole within torque tube TT. In cases of brackets 100 having
secondary pull holes 122, such as shown at FIG. 1B, pull holes 122
can be used as points to secure wrench W when attaching left and
right brackets 100L/R to torque tube TT, as depicted at FIG. 1G.
Wrench W can be leveraged about torque tube TT to pull rivet holes
121 of overlapping rivet tabs 120 into position for riveting to
torque tube TT.
[0030] The installer can use the torque tube as a pivot to rest the
weight of the module on, held in place by collar portion 115 while
the assembly (collars and photovoltaic module PVM) are rotated
about torque tube TT until orientation tabs 125 on either side of
the module rests in its corresponding opening in the torque tube.
Bracket 100 may also include an additional rivet hole 126, as shown
at FIG. 1A, that allows one bracket 100 to be riveted to an
adjacent bracket, further strengthening the attachment of the
modules to the torque tube. Using bracket 100, post-installation
disconnection of a particular module requires simply cutting or
grinding the rivet or removing the other mechanical fastener
connecting bracket 100 to the torque tube, and if applicable, to
the adjacent saddle bracket.
[0031] FIG. 1H shows an alternative construction of bracket 100
that shares many of the same numbered aspects of the brackets
depicted at FIGS. 1A and 1B. However, here, no alignment tab is
present, but rather two rivet tabs 120 are provided for double
riveting of bracket 100 to a torque tube. In addition, collar
portion 115 includes location tab 117 that can insert into a
supplementary opening of a torque tube. Location tab 117 serves to
help maintain bracket 100 in position while rivets can be secured
to rivet tabs 120.
[0032] FIG. 1I shows another alternative construction of bracket
100 that shares many of the same numbered aspects of the brackets
depicted at FIGS. 1A and 1B. However, here rivet tab 120 and
alignment tab 125 are not coplanar with a plane that wall member
101 extends along. Accordingly, sharing of mounting holes on a
common torque tube between adjacent brackets 100 is not intended or
needed. Such a bracket 100 can be used at ends of a tracker array,
or when an individual set of mounting holes per bracket 100 is
desired. In addition, here alignment tab 125 is configured to have
a separate body that bolts to a portion of wall member 101 by way
of fasteners 127, which can be bolts or rivets for example.
Alignment tab 125 can be constructed from a stamped or cast metal
body for example, and be configured to use one or more fasteners
for attachment to wall member 101.
[0033] Referring now to FIG. 2, this figure shows another
photovoltaic mounting system for attaching solar panels to a torque
tube. Saddle bracket 200 is similar to saddle bracket 100 with a
few notable differences. First, saddle bracket 200 is not
handed--in other words, the same bracket may be used for either
side of a PV module. Also, as shown, bracket 200 is two-sided, so a
single bracket will connect to PV modules on both sides of bracket
200. This can reduce the number of brackets from 2.times. the
number of PV modules to 1.times. the number of modules +1.
[0034] Similar to bracket 100, bracket 200 can have a collar
portion 215 that fits around the torque tube that may include pair
of rivet tabs 220 that match up with holes fabricated in the torque
tube. It should be appreciated that a rivet is not the only
possible means of attachment--a screw, bolt, or other suitable
fastener could be used with rivet tabs 220 to attach saddle bracket
200 to the torque tube.
[0035] Bracket 200 can have at least two pairs of opposing ledge
portions 205 that support the frame of a PV module from below.
Bracket 200 can also have a plurality of attachment tabs 210 that
serve to bias the frame of a PV module against the opposing ledge
portions 205 on either side of bracket 200.
[0036] During installation, at least one bracket 200 can be
installed directly to the torque tube first, before any PV modules
are placed. Then, a PV module with an identical bracket
pre-attached to other side can be pivoted in at an angle and
pressed down to bend back attachment tabs 205 until the module
frame rests on one set of ledge portions 205 and the alignment tab
returns back to the rest position with the downturned edge of the
tab pressing against the top of the module frame. Then the next
module can be placed in the same manner, and so on and so forth
until all modules have been attached to the torque tube. The
modules can have a timing mark or other feature to inform the
installer as to the desired position of the module with respect to
saddle bracket 200 so that all modules are attached to the brackets
at the same place along the module frame, such as, for example, at
or near the middle of the module frame. Given its substantially
uniform construction, the middle should roughly correspond the
center of mass.
[0037] Using saddle bracket 200, disconnection of a particular
module may be accomplished using a special tool to push the
attachment tabs holding that module down on either side out of the
way to release the module from tabs 210.
[0038] Referring now to FIGS. 3A and 3B, these figures shows yet
another photovoltaic mounting system for attaching PV modules to a
torque tube according to various embodiments of the invention.
Bracket 300 can include collar portion 308 with rivet tabs 330 that
are used to attach bracket 300 to a torque tube. Like bracket 200,
bracket 300 can be first attached to the torque tube using rivets
or other suitable mechanical fasteners before any PV modules are
attached.
[0039] Bracket 300 can also have a pair of opposing module ledges
305 on either side of vertical spine portion 310. This enables
modules to be installed on either side of bracket 300 requiring
1.times. the number of modules +1 such brackets per torque tube. At
one end of spine portion 310, bracket 300 can have several
attachment tabs 315 that bias the frames of adjacent PV modules
down against ledge 305.
[0040] The other end of vertical spine portion 315 can include
rotating cam lock 320 that is used to manually lock down a pair of
PV modules after they are placed on either side of bracket 300. In
various embodiments lever portion 325 is rotated down to free cam
lock 320 to the relaxed position as depicted at FIG. 3A. After two
modules are set, lever portion 325 is rotated to effect a
corresponding rotation of cam lock 320 so that it covers a portion
of the frame of each module instead of covering spine portion 310.
Then, lever portion 325 is pressed upwards thereby pulling down on
cam lock 320 to bias the module frames against shelf portion 305,
as depicted at FIG. 3B. Although in the figure, lever portion 325
is designed for manual adjustment, it is possible that in other
embodiments, a tool may be used to facilitate the locking and
unlocking process.
[0041] Referring now to FIG. 4, this figure shows a photovoltaic
mounting system for attaching PV modules to a torque tube according
to further embodiments of the invention. This system includes
bracket 400. Bracket 400 is similar to bracket 200 in that it is a
two-sided bracket. Bracket 400 can include collar portion 420,
which in turn can include torque tube rivet tabs 425 for attaching
bracket 400 to a torque tube. Opposing ledge portions 410 can be
located at either side of main body 405 to support the frames of
two adjacent PV modules. Bracket 400 can also include opposing
attachment tabs 415, some of which face one side and others of
which face the opposing side.
[0042] One feature that distinguishes bracket 400 from other
brackets disclosed herein (e.g., 100, 200, & 300), is that half
of attachment tabs 415 have a bolt 416 that enables the tab to be
removed from below. With this configuration, every module will have
one set of attachment tabs that are removable, making it easier to
remove a defective/non-functional module without having to remove
the collar. This is discussed in greater detail in the context of
FIGS. 11A and 11B. This bolting arrangement is not exclusive to
bracket 400, and can be used with any of the brackets disclosed
herein.
[0043] Referring now to FIGS. 5-10C, these figures show various
steps in the installation of PV modules onto a tracker array using
the saddle bracket 400 of FIG. 4. For example, starting with FIG.
5, the first bracket 400 is installed on the torque tube by
riveting it or otherwise affixing it through rivet tabs 425. Then,
as shown in FIG. 6A, the first module is pivoted down under the
detachable attachment tabs 415. As seen in FIG. 6A, in various
embodiments, the detachable attachment tabs, that is the ones with
bolts 416 may be shaped differently (e.g., 400B) than the other
attachment tabs (e.g., 400A) because one bracket is already
pre-attached to the torque tube when the module is attached and the
other is not.
[0044] As seen at FIG. 7, in various embodiments the next saddle
bracket 400 is attached to the PV module off of the torque tube so
that when each module is pivoted under the attached bracket 400 it
already has a bracket on the other side that can then be riveted to
the torque tube. So each time a subsequent module is dropped on the
torque tube to be attached to an existing saddle bracket, it will
provide another existing open saddle bracket for the next module,
and so on, and so forth until all modules have been attached to the
torque tube. This sequence is depicted at FIGS. 8A to 8C. At FIG.
8A, module PVM and attached right-most bracket 400 is placed onto
torque tube TT, which already has left most located bracket 400
attached. Then, at FIG. 8B the module PVM is slid towards the
pre-attached bracket until the configuration of FIG. 8C is
achieved.
[0045] FIGS. 9A and 9B show with greater detail how a PV module
with an attached saddle bracket is slid into a pre-installed saddle
bracket. The upturned lip on the attachment tab 415 allows the
module to be slid underneath it without catching. Because the other
saddle bracket is attached off of the torque tube, it doesn't
require the upturned lip. FIG. 10 shows how the process is repeated
with additional modules. A next module with one attached saddle
bracket is dropped down on the torque tube so that the collar
portion 420 engages the torque tube. Then, it is slid laterally
along the torque tube in the direction of the pre-attached saddle
bracket until the module clicks under it (as seen in FIG. 9C).
[0046] FIGS. 11A and 11B shows the process for removing a module
that is attached using saddle bracket 400, or any bracket using
removable holding tabs. This may need to be done, for example, if a
module, junction box, or other component fails. The process is
accomplished by removing bolt 416 holding tab 415B on to saddle
bracket 400. This can be done from underneath the module, as shown
at FIG. 11A, making it easier for the technician and eliminating
the need to rotate torque tube TT to a particular orientation so
that the technician can get above the array. After tabs 415B have
been removed, the module can simply be pushed up from the bottom.
This will release it from tabs 415A of the opposing saddle bracket.
A new module can simply dropped down in and tabs 415B re-attached
to lock it in place.
[0047] The various embodiments of the invention have been discussed
in the context of a single axis tracker, however, it should be
appreciated that the saddle brackets discussed herein may also be
usable with a dual-axis tracker or even possibly a stationary
ground mounted solar array. Furthermore, the drawings included
herewith are exemplary only and are not intended to limit the
various embodiments of the invention to a particular geometry,
design or materials. Those of ordinary skill in the art will
understand and appreciate that various modifications and/or
substitutions may be made without departing from the spirit or
scope of the invention.
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